belt DODGE NEON 2000 Service Owners Manual

BODY COMPONENTS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
GRILLE................................13
HOOD.................................13
FRONT DOOR...........................14
SPLASH SHIELD.........................16
DIAGNOSIS AND TESTING
WATER LEAKS..........................18
WIND NOISE............................19
SERVICE PROCEDURES
HEAT STAKING..........................19
PLASTIC BODY PANEL REPAIR..............19
REMOVAL AND INSTALLATION
GRILLE................................23
HOOD LATCH...........................24
HOOD LATCH STRIKER....................24
HOOD RELEASE CABLE...................25
HOOD.................................26
HOOD SILENCER........................26
HOOD HINGE...........................26
COWL COVER...........................27
FRONT WHEELHOUSE SPLASH SHIELD......28
FENDER...............................28
EXTERIOR BADGEING ATTACHED WITH
DOUBLE SIDED FOAM TAPE..............28
EXTERIOR BADGEING/TAPE STRIPES
ATTACHED WITH ADHESIVES.............28
FRONT/REAR DOOR WINDOW CRANK........29
FRONT DOOR TRIM......................30
FRONT DOOR WATER DAM................30
DOOR OUTER BELT WEATHERSTRIP.........30
FRONT/REAR DOOR INNER BELT
WEATHERSTRIP........................32
FRONT DOOR GLASS RUN WEATHERSTRIP . . . 32
FRONT DOOR OUTSIDE HANDLE............33
DOOR LOCK CYLINDER...................33
FRONT DOOR LATCH.....................33
FRONT DOOR LATCH STRIKER.............34
FRONT VERTICAL GUIDE BAR..............34
FRONT DOOR GLASS.....................36
FRONT DOOR CHECK STRAP..............36
FRONT DOOR...........................36
FRONT DOOR HINGE.....................38
FRONT/REAR DOOR APPLIQUE.............38
SIDE VIEW MIRROR......................39
SIDE VIEW MIRROR TRIM BEZEL............39
DOOR UPPER SECONDARY WEATHERSTRIP . . 39
SILL SECONDARY WEATHERSTRIP..........40
REAR DOOR TRIM.......................40REAR DOOR WATER DAM.................40
REAR DOOR OUTSIDE HANDLE.............40
REAR DOOR LATCH......................41
REAR DOOR LATCH STRIKER..............43
REAR DOOR GLASS......................43
REAR DOOR WINDOW REGULATOR.........43
REAR DOOR GLASS RUN WEATHERSTRIP....43
REAR DOOR CHECK STRAP................45
REAR DOOR............................45
REAR DOOR HINGE......................45
FUEL FILL DOOR.........................46
DECKLID LATCH.........................47
DECKLID...............................47
DECKLID LIFT SPRINGS...................47
DECKLID LOCK CYLINDER.................48
DECKLID LATCH STRIKER.................48
DECKLID OPENING WEATHERSTRIP.........49
TRUNK CARPET.........................49
DECKLID COVER.........................50
ROOF RAIL WEATHERSTRIP................50
ROOF RAIL WEATHERSTRIP RETAINER
CHANNEL.............................50
B-PILLAR WEATHERSTRIP CHANNEL.........51
A-PILLAR TRIM..........................51
DOOR SILL TRIM.........................51
SIDE COWL TRIM........................52
B-PILLAR TRIM..........................52
UPPER QUARTER TRIM...................53
LOWER QUARTER TRIM...................53
FLOOR CONSOLE........................54
FRONT SEAT BELT BUCKLE................54
FRONT SEAT BELT RETRACTOR............54
FRONT SHOULDER BELT ADJUSTER.........54
REAR SEAT BELT BUCKLE.................55
REAR SEAT BELT RETRACTOR.............55
CARPET...............................56
SUN VISOR.............................56
HEADLINER.............................57
INSIDE REAR VIEW MIRROR...............57
REAR SHELF TRIM PANEL.................57
BODY VENT.............................58
ADJUSTMENTS
FRONT DOOR LATCH ADJUSTMENT.........58
REAR DOOR LATCH ADJUSTMENT..........58
SPECIFICATIONS
BODY LUBRICATION......................59
SPECIAL TOOLS
BODY.................................59
23 - 12 BODYPL

INSTALLATION
(1) Place the lock clip on the window crank.
(2) Place window crank on regulator shaft with the
window in the down position.
(3) Orientate the window regulator crank handle
appropriately at the 10 o'clock position and the left
handle at the 2 o'clock position.
(4) Push the handle in to the lock position on the
regulator shaft.
FRONT DOOR TRIM
REMOVAL
(1) Release door latch and open door.
(2) Lower door glass.
(3) Remove window regulator crank, if so equipped
(Fig. 26).
(4) Remove screw from inside arm rest pull cup
(Fig. 27).
(5) Remove screw from behind inside latch release
handle.
(6) Disengage push-in fasteners attaching trim to
door panel around perimeter of trim panel.
(7) Tilt trim panel outward to clear locator pins on
backside of trim panel.
(8) Disconnect trim panel from retainer channel in
inner belt weatherstrip at top of door by lifting while
gently jiggling.
(9) Move trim panel away from door and disengage
clip attaching latch rod to handle.
(10) Remove latch rod from handle.
CAUTION: Do not allow door trim panel to hang by
the wire connector or wiring.(11) Disconnect wire connector from power door
lock switch, mirror switch, and power window switch
if so equipped.
(12) Remove trim panel from door.
INSTALLATION
(1) Replace any damaged or missing push in fas-
teners from around perimeter of door trim panel.
(2) Place trim panel near door.
(3) Connect wire connector into power door lock
switch, mirror switch, and power window switch, if
so equipped.
(4) Insert latch rod into handle and engage clip.
(5) Install trim panel into retainer channel at top
of door and push down to seat.
(6) Locate door trim panel to inner door panel by
aligning locating pins on backside of trim panel to
mating holes in inner door panel.
(7) Install push in fasteners to hold trim to door
panel around perimeter of trim panel.
(8) Install screw inside latch release handle.
(9) Install screw inside arm rest pull cup.
(10) With the window in the down position, orien-
tate the window regulator crank handle appropri-
ately. Install the right handle at the 10 o'clock
position and the left handle at the 2 O'clock position,
if so equipped.
FRONT DOOR WATER DAM
REMOVAL
(1) Remove door trim panel.
(2) Remove door speaker, if equipped.
(3) Remove door trim pull cup mount bracket.
(4) Disconnect clip attaching lock linkage to lock
button bell-crank.
(5) Peel water dam away from adhesive around
perimeter of inner door panel (Fig. 28).
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the water dam into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Engage clip attaching lock linkage to lock but-
ton bell-crank.
(4) Install door trim pull cup mount bracket.
(5) Install door speaker, if equipped.
(6) Install door trim panel.
DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(1) Open door glass.
Fig. 26 Window Crank
1 ± WINDOW CRANK REMOVAL TOOL
2 ± WINDOW CRANK
23 - 30 BODYPL
REMOVAL AND INSTALLATION (Continued)

(2) Pull upward at rear end of outer belt weather-
strip.
(3) Remove outer belt weatherstrip from vehicle
(Fig. 29).INSTALLATION
(1) Starting at leading edge of door, press weather-
strip onto door.
(2) Operate window and check for interference
Fig. 27 Front Door Trim
1 ± FRONT DOOR
2 ± LINK AND SLEEVES
3 ± INNER REMOTE HANDLE
4 ± POWER DOOR LOCK SWITCH5 ± DOOR TRIM SCREWS
6 ± FRONT DOOR TRIM PANEL
7 ± INSIDE DOOR HANDLE
Fig. 28 Water Dam
1 ± U NUTS
2 ± LINK AND SLEEVES
3 ± FRONT DOOR4 ± WATER DAM
5 ± TRIM ATTACHING BRACKET
PLBODY 23 - 31
REMOVAL AND INSTALLATION (Continued)

FRONT/REAR DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove door trim panel.
(2) Remove weatherstrip from door. Use a rubber
mallet and a block of wood, tap upward at each clip
holding the molding to the door (Fig. 30).
INSTALLATION
(1) Push down on weatherstrip to engage channel
to door panel.
(2) Install door trim panel.
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL
(1) Remove flag cover, door trim panel, water dam
as necessary.
(2) Remove door glass.
(3) Loosen side view mirror, as necessary.
(4) Remove weatherstrip fasteners.
(5) Pull weatherstrip from lower front channel
above door latch.
(6) Pull run weatherstrip from window frame
channel (Fig. 31).
INSTALLATION
(1) Clean butyl material from door flange area.
(2) Place door run weatherstrip in position on win-
dow frame channel.
(3) Push door run weatherstrip into window frame
channel.
(4) Push weatherstrip into lower front channel
above door latch.
(5) Install weatherstrip fasteners.
(6) Install door glass.
(7) Tighten side view mirror.
(8) Install pull cup support bracket, water shield,
door trim panel and flag trim.
Fig. 29 Door Outer Belt Weatherstrip
1 ± REAR DOOR OUTER BELT WEATHERSTRIP
2 ± FRONT DOOR OUTER BELT WEATHERSTRIP3 ± DOOR MOLDING
4 ± OUTER BELT WEATHERSTRIP
Fig. 30 Front/Rear Door Inner Belt Weatherstrip
1 ± REAR DOOR
2 ± FRONT DOOR
3 ± INNER BELT WEATHERSTRIP
23 - 32 BODYPL
REMOVAL AND INSTALLATION (Continued)

FRONT DOOR GLASS
REMOVAL
(1) Remove door trim panel and water dam.
(2) Remove inner door belt weatherstrip.
(3) Loosen window inner belt stabilizer.
(4) Lower door glass to bottom of door to gain
access to attaching bolts.
(5) Remove bolts attaching door glass to window
regulator lift plates (Fig. 36).
(6) Disengage door glass from regulator.
(7) Lift door glass upward out of the opening at
the top of door.
INSTALLATION
(1) Carefully lower door glass through opening in
top of door.
(2) Position door glass into window regulator lift
plates.
(3) Install bolts door glass to lift plates and do not
tighten.
(4) Tighten window inner belt stabilizer.
(5) Raise glass to the full up position and then
tighten the lift plate bolts.
(6) Install inner door belt weatherstrip.
(7) Install door trim panel and water dam.
FRONT DOOR CHECK STRAP
REMOVAL
(1) Remove door trim panel and water dam.(2) Remove bolt attaching check strap to hinge pil-
lar.
(3) Remove door speaker.
(4) Remove glass run.
(5) Remove bolts attaching check strap to door end
frame (Fig. 38).
(6) Remove check strap from vehicle.
INSTALLATION
NOTE: Do not grease check strap.
(1) Position door check on vehicle and install bolts
attaching strap to door end frame.
(2) Install glass run.
(3) Install door speaker, if so equipped.
(4) Install bolt attaching door check strap to hinge
pillar.
(5) Install door trim panel and water dam.
FRONT DOOR
REMOVAL
NOTE: The retaining clips used on the door hinge
pins are not to be reused. Verify availability prior to
proceeding.
(1) Open and support door on a suitable lifting
device.
Fig. 36 Front Door Glass ± Power Window
1 ± FRONT DOOR GLASS
2 ± FRONT DOOR
3 ± POWER WINDOW REGULATOR4 ± POWER WINDOW CONNECTORS
5 ± WINDOW TO REGULATOR FASTENER
23 - 36 BODYPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position weatherstrip to opening door.
(2) Press door upper secondary weatherstrip fas-
teners into position.
SILL SECONDARY WEATHERSTRIP
REMOVAL
(1) Using a fork-type prying tool, disengage push
in fasteners attaching sill secondary weatherstrip to
door (Fig. 42).
(2) Remove weatherstrip from door.
INSTALLATION
(1) Position weatherstrip to door.
(2) Press sill secondary weatherstrip fasteners into
position.
REAR DOOR TRIM
REMOVAL
(1) Release door latch and open door.
(2) Lower window glass.
(3) Remove window regulator crank.
(4) Remove screw from inside arm rest pull cup.
(5) Remove screw from behind inside latch release
handle (Fig. 43).
(6) Disengage push in fasteners attaching trim to
door panel around perimeter of trim panel.
(7) Disengage push-in metal spring clip holding
trim in sail flag area.
(8) Lift trim panel up off belt weatherstrip.(9) Tilt top of trim panel away from door and dis-
engage clip attaching latch rod to handle.
(10) Remove latch rod from handle.
(11) Remove trim panel from door.
INSTALLATION
(1) Replace any damaged or missing push in fas-
teners from around perimeter of door trim panel.
(2) Place trim panel in position on door.
(3) Insert latch rod into handle and engage clip.
(4) Engage trim panel into retainer channel at top
of door.
(5) Locate door trim panel to inner door panel by
aligning locating pins on backside of trim panel to
mating holes in inner door panel.
(6) Engage push in fasteners attaching trim to
door panel around perimeter of trim panel.
(7) Install screw behind inside latch release han-
dle.
(8) Install screw inside arm rest pull cup.
(9) Install window regulator crank.
REAR DOOR WATER DAM
REMOVAL
(1) Remove door trim panel.
(2) Remove door speaker, if equipped.
(3) Remove door trim pull cup mount bracket.
(4) Disconnect clip attaching lock linkage to lock
button bell-crank.
(5) Peel water dam away from adhesive around
perimeter of inner door panel (Fig. 44).
INSTALLATION
(1) Insure that enough adhesive remains to
securely retain the water dam. Replace as necessary.
(2) Place the water dam into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(3) Engage clip attaching lock linkage to lock but-
ton bell-crank.
(4) Install door trim pull cup mount bracket.
(5) Install door speaker, if equipped.
(6) Install door trim panel.
REAR DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove door trim panel.
(2) Close door glass.
(3) Disengage clips attaching linkage rods to door
handle.
(4) Remove nuts attaching outside handle to door
(Fig. 45).
(5) Remove outside handle.
Fig. 42 Front/Rear Sill Secondary Weatherstrip
1 ± FRONT DOOR
2 ± REAR DOOR
3 ± SILL SECONDARY WEATHERSTRIP
23 - 40 BODYPL
REMOVAL AND INSTALLATION (Continued)

(1) Position door latch on vehicle and install
screws attaching latch to door end frame.
(2) Connect linkage rods to latch.
(3) Connect lock and latch rods to door latch.
(4) Tighten lower rear run channel.
(5) Install door trim panel.
REAR DOOR LATCH STRIKER
REMOVAL
(1) Mark outline of door latch striker on B-pillar to
aid installation.
(2) Remove screws attaching door latch striker to
B-pillar (Fig. 47).
(3) Remove door latch striker from vehicle.
INSTALLATION
(1) Install door latch striker from vehicle.
(2) Install screws attaching door latch striker to
B-pillar.
(3) Align marked outline of door latch striker on
B-pillar to aid installation.
REAR DOOR GLASS
REMOVAL
(1) Remove door trim panel and inner belt weath-
erstrip.
(2) Lower the window to 50 mm (2 ins.) from bot-
tom of travel.
(3) Loosen bolts attaching rear lower run channel
to inner door panel (Fig. 47).
(4) Remove rear run channel from door.
(5) Loosen screws attaching window regulator
channel to glass.
(6) Slide channel rearward to allow screw heads to
pass through key hole slots in channel.
(7) Remove glass from roller channel.
(8) Lift door glass upward out of the opening at
the top of door.
INSTALLATION
(1) Lower door glass through opening in top of
door and into position in the window regulator.
(2) Position door glass onto roller channel.
(3) Slide roller channel forward to allow screw
heads to engage key hole slots in channel.
(4) Tighten screws attaching window regulator
roller channel to glass.
(5) Install inner door belt door trim panel inner
belt weatherstrip.
(6) Operate window and check for interference.
Adjust glass as necessary.
REAR DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door trim panel.
(2) Remove door glass from regulator channel.
(3) Loosen screws attaching window regulator
channel and crank housing to door panel (Fig. 47).
(4) Disengage screw and bolt heads from keyhole
slots in door panel.
(5) Loosen bolts attaching window regulator to
door panel.
(6) Disengage regulator from door panel, and
crank housing.
(7) Slide regulator rearward and rotate forward
end of roller channel through access hole in door
panel,
(8) Remove window regulator from door through
access hole in inner panel.
INSTALLATION
(1) position window regulator and crank housing
on door panel through access hole in door panel.
(2) Tighten bolts attaching window regulator to
door panel.
(3) Engage window regulator bolt heads on chan-
nel to key hole slots in door panel.
(4) Tighten screw attaching window regulator
channel and crank housing.
(5) Position glass to regulator roller channel.
(6) Tighten fasteners attaching door glass to roller
channel.
(7) Install door trim panel.
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL
(1) Remove door trim panel, water dam as neces-
sary.
(2) Remove door glass.
(3) Remove weatherstrip fasteners.
(4) Pull weatherstrip from lower front channel
above door latch.
(5) Pull run weatherstrip from window frame
channel (Fig. 48).
INSTALLATION
(1) Clean butyl material from door flange area.
(2) Place door run weatherstrip in position on win-
dow frame channel.
(3) Push door run weatherstrip into window frame
channel.
(4) Push weatherstrip into lower front channel
above door latch.
(5) Install weatherstrip fasteners.
(6) Install door glass.
PLBODY 23 - 43
REMOVAL AND INSTALLATION (Continued)

(3) Engage clips on trim panel into slots in door
sill.
(4) Engage clips on trim panel onto door opening
flange.
(5) Press downward on trim panel to fully engage
all clips.
SIDE COWL TRIM
REMOVAL
(1) Disengage clips attaching cowl trim to cowl
side panel.
(2) Remove cowl trim from vehicle (Fig. 63).
INSTALLATION
(1) Position cowl trim panel to inner cowl panel.
(2) Align locating pins on backside of cowl trim
panel to mating holes in inner cowl panel.
(3) Push clips on trim panel into slots in inner
cowl panel.
B-PILLAR TRIM
REMOVAL
(1) Remove bolt attaching lower seat belt anchor to
floor pan kick-up (Fig. 64).
(2) Remove shoulder belt height control knob.
(3) Remove bolt attaching turning loop to belt
adjuster (Fig. 65).
(4) Remove access cover from B-pillar trim.
(5) Disengage clips attaching trim to B-pillar.
(6) Feed seat belt turning loop and seat belt
through trim panel.
(7) Remove B-pillar trim from vehicle.
INSTALLATION
NOTE: Tighten all seat belt bolts to 40 N´m (40 ft.
lbs.) torque.
(1) Position B-pillar trim panel near B-pillar.
(2) Feed seat belt turning loop and seat belt
through trim panel.
(3) Align locating pins on backside of trim panel to
mating holes in B-pillar.
(4) Push clips on trim panel into slots in B-pillar.
(5) Install access cover to B-pillar trim.
Fig. 61 A-pillar Trim
1 ± WINDSHIELD A-PILLAR
2 ± CLIPS
3 ± A-PILLAR TRIM
Fig. 62 Door Sill Trim
1 ± FRONT DOOR SILL
2 ± REAR DOOR SILL
3 ± SILL TRIM
Fig. 63 Side Cowl Trim
1 ± DOOR OPENING
2 ± COWL
3 ± SILL
4 ± COWL TRIM
23 - 52 BODYPL
REMOVAL AND INSTALLATION (Continued)

(6) Install bolt attaching turning loop to belt
adjuster.
(7) Move adjuster in to the lowest position.
(8) Install shoulder belt height control knob.
(9) Install bolt attaching lower seat belt anchor to
floor pan kick-up.
UPPER QUARTER TRIM
REMOVAL
(1) Disengage clips attaching trim to upper quar-
ter panel (Fig. 66).
(2) Remove upper trim panel from vehicle.
INSTALLATION
(1) Check to ensure that electric rear window wir-
ing is positioned correctly in the roof channel pro-
vided.
(2) Position trim panel in vehicle.
(3) Align locating pins on backside of trim panel to
mating holes in upper quarter panel.
(4) Push clips on trim panel into slots in upper
quarter panel.
LOWER QUARTER TRIM
REMOVAL
(1) Remove upper quarter trim panel.
(2) Remove rear seat cushion and back.
Fig. 64 B-pillar Trim
1 ± FRONT SEAT BELT ADJUSTER
2 ± UPPER B-PILLAR TRIM PANEL
3 ± ADJUSTER BUTTON
4 ± TURNING LOOP
5 ± SEAT BELT
6 ± SEAT BELT RETRACTOR
7 ± ANCHOR BOLT
8 ± LOWER B-PILLAR TRIM PANEL
Fig. 65 Turning Loop to Belt Adjuster
1 ± FRONT SHOULDER BELT ADJUSTER
2 ± TAB IS ON BOTTOM
Fig. 66 Upper Quarter Trim
1 ± UPPER QUARTER TRIM PANEL
2 ± LOWER QUARTER TRIM PANEL
3 ± SEAT BELT
PLBODY 23 - 53
REMOVAL AND INSTALLATION (Continued)

(3) Disengage clips attaching trim to lower quarter
panel.
(4) Remove seat belt from slot in trim panel.
(5) Remove lower quarter trim from vehicle (Fig.
66).
INSTALLATION
(1) Position lower quarter trim panel to vehicle.
(2) Install seat belt to slot in trim panel.
(3) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(4) Press clips on trim panel into slots in inner
quarter panel.
(5) Install rear seat back and cushion.
(6) Install upper quarter trim panel.
FLOOR CONSOLE
REMOVAL
(1) Fully apply parking brake.
(2) Remove screw cover plugs over screws just
rearward of cup holders.
(3) Remove screws in cup holders attaching con-
sole to floor bracket.
(4) Open console storage compartment lid, if so
equipped.
(5) Remove screw cover plugs over screws near
rear of console.
(6) Remove screws attaching console to floor
bracket.
(7) Remove shift lever knob, if vehicle is equipped
with a manual transmission.
(8) Lift console upward over gear selector and park
brake handle.
(9) Remove console from vehicle.
INSTALLATION
(1) Place floor console into position in vehicle.
(2) Install screws attaching console to floor brack-
ets.
(3) Install screw cover plugs.
(4) Install shift lever knob, if vehicle is equipped
with a manual transmission.
(5) Release parking brake.
FRONT SEAT BELT BUCKLE
CAUTION: Front seat belt assemblies must be
replaced after a collision.
REMOVAL
(1) Remove bolt attaching seat belt buckle from
seat anchor.
(2) Remove seat belt buckle from seat.
INSTALLATION
(1) Place seat belt buckle in position on seat
anchor.
(2) Install bolt attaching seat belt buckle to seat
anchor. Tighten seat belt anchor bolt to 40 N´m (30
ft. lbs.) torque.
FRONT SEAT BELT RETRACTOR
CAUTION: Front seat belt assemblies must be
replaced after a collision.
REMOVAL
(1) Remove B-pillar trim.
(2) Remove bolt attaching seat belt retractor to
B-pillar (Fig. 68).
(3) Remove seat belt retractor from vehicle.
INSTALLATION
(1) Install seat belt retractor into vehicle.
(2) Install bolt attaching seat belt retractor to
B-pillar. Tighten seat belt anchor bolt to 40 N´m (30
ft. lbs.) torque.
(3) Install B-pillar trim.
FRONT SHOULDER BELT ADJUSTER
CAUTION: Front seat belt assemblies must be
replaced after a collision.
REMOVAL
(1) Remove B-pillar trim (Fig. 68).
Fig. 67 Floor Console
1 ± FLOOR CONSOLE WITH ARMREST
2 ± ATTACHING SCREWS
23 - 54 BODYPL
REMOVAL AND INSTALLATION (Continued)